Abstract
The For more than a hundred years, the four-stroke engine has remained a primary power source in automotive and industrial systems due to its dependable operation and effective energy conversion. Among its critical components, the piston plays a central role by moving reciprocally within the cylinder and transferring the force produced by fuel combustion to the crankshaft through the connecting rod. This motion enables the transformation of the fuel’s chemical energy into mechanical power required for engine operation. During engine functioning, the piston is exposed to extreme conditions such as high combustion temperatures, intense gas pressure, and continuous cyclic loading. These harsh operating environments make piston design and material selection extremely important for ensuring engine reliability, thermal stability, and long service life. An efficient piston must combine high strength, low weight, and good thermal conductivity while resisting deformation and wear. The present work investigates the design and performance analysis of a four-stroke engine piston using two different materials, namely aluminum alloy and cast iron. To maintain consistency and accuracy in comparison, identical piston dimensions are used for both materials. The geometric modeling of the piston is carried out using CATIA V5, while the numerical simulations are performed with ANSYS Workbench. The analysis covers thermal, structural, and mechanical behavior, including temperature distribution, pressure loading effects, stress development, and strain response under operating conditions. The comparative results obtained from this study highlight the influence of material properties on piston performance and provide a basis for selecting suitable materials to enhance engine efficiency, durability, and overall operational effectiveness.
Keywords
Catia V5, Anasys Workbench 15.0, Temperature, Pressure, Stress
Citations
IRE Journals:
Amit "A Study on Design Optimization and Performance Analysis of A Four-Stroke Engine Piston" Iconic Research And Engineering Journals Volume 9 Issue 7 2026 Page 2931-2935
IEEE:
Amit
"A Study on Design Optimization and Performance Analysis of A Four-Stroke Engine Piston" Iconic Research And Engineering Journals, 9(7)
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